Disassembly and Assembly

Differential Case and Ring Gear

Special Tool(s):

Material:

Disassembly
1. Remove the differential case.
2. Remove the 10 differential ring gear bolts.





3. CAUTION: Do not damage the differential ring gear bolt hole threads.

Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.





4. Using the special tools, remove the differential bearings.





5. Remove the differential pinion shaft lock bolt.





6. Remove the differential pinion shaft.





7. Rotate and remove the differential pinion gears and differential pinion gear thrust washers.





8. Remove the differential side gears and the differential side gear thrust washers.





Assembly
1. Lubricate the differential side gear thrust washer and the differential side gear journals with axle lube, then position the differential side gear thrust washers on the differential side gears.





2. Install the differential side gears.





3. Using axle lubricant, lubricate the differential pinion gear thrust washers and the differential pinion gears.





4. Install the differential pinion gears and differential pinion gear thrust washers opposite the differential side gears.





5. Rotate the differential pinion gears to align with the differential pinion shaft bore.





6. Install the differential pinion shaft.
^ Align the hole in the differential pinion shaft with the hole in the differential case.





7. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer.

Install a new differential pinion shaft lock bolt and finger-tighten.





8. Using the special tool, install new differential bearings.




9. Press the differential ring gear on the differential assembly.





10. Apply Stud and Bearing Mount to the differential ring gear bolt threads and install the differential ring gear bolts.
^ Tighten to 105 Nm (77 ft. lbs.).





11. Install the differential case.